System and method for modular building plant oil extraction room

ABSTRACT

An extraction room in a modular cube structure includes a processing enclosure, an equipment enclosure, and an exhaust stack. A first wall of the exhaust stack forms an interior wall of the processing enclosure. A second wall of the exhaust stack forms an exterior wall of the extraction room. The exhaust stack extends through the equipment enclosure to an ambient space external to the extraction room.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of the filing date of U.S. Provisional Application No. 62/640,613 filed on Mar. 9, 2018, which is hereby incorporated by reference in its entirety.

BACKGROUND

This description relates to processing vegetable matter containing oils and waxes and, more particularly, to an extraction room of a modularly constructed building for processing bio-matter into a valuable oil product.

Processing bio-matter includes using a plant and/or animal feedstock along with various compounds, mixtures and/or elements to extract one or more valuable oil products from the bio-matter.

Cannabis legalization in several jurisdictions has led to strong demand for products made from the oils and chemical compounds that can be extracted from Cannabis (referred to herein as “extracts” or “valuable oil products”) and used by individuals without smoking the plant itself. For example, demand has grown in the areas of Pharmaceuticals commonly referred to as “medical marijuana,” and in nutritional supplements, edible products, and vaporizer fluids to name a few. Cannabis extracts are traditionally made by exposing cannabis plants to carbon dioxide, butane, propane, alcohol, glycerin, and/or other solvents in a vessel or mixer to leach the extracts from cannabis plants.

Some of the processes involved in extracting the valuable oil products from a biomass of oil-laden material use solvents that can be hazardous if not handled properly. Ways to alleviate hazards involved with such solvents include ventilation of spaces where such solvents are used, limiting tools and equipment in the spaces to non-sparking materials, and providing breathing air for workers until they can exit the affected space. Such solutions benefit from a specialized design of the facility where these processes are performed.

To capitalize on first-to-market advantages, facilities that incorporate these designs can be supplied by modular building techniques in a controlled environment. The modular facility is more efficient at extracting such compounds, safer, and can be positioned at a site quicker than other construction methods.

BRIEF DESCRIPTION

In one aspect, an extraction room in a modular cube structure includes a processing enclosure, an equipment enclosure, and an exhaust stack. A first wall of the exhaust stack forms an interior wall of the processing enclosure. A second wall of the exhaust stack forms an exterior wall of the extraction room. The exhaust stack extends through the equipment enclosure to an ambient space external to the extraction room.

In another aspect, a method of extracting a component of a quantity of bio-matter includes maintaining a first flow of diluent through a processing enclosure of a multi-enclosure extraction room of a modular cube structure. The extraction room includes an equipment enclosure and an exhaust stack. The method includes discharging the first flow of diluent from the processing enclosure to the exhaust stack wherein a first wall of the exhaust stack forms an interior wall of the processing enclosure, a second wall of the exhaust stack forms an exterior wall of the extraction room, and the exhaust stack extends through the equipment enclosure to an ambient space external to the extraction room. The method also includes monitoring a concentration of at least one solvent of a plurality of solvents used in the extraction process, receiving a container of bio-matter into the processing enclosure, and maintaining a second flow of diluent through a processing enclosure when the concentration of the at least one monitored solvent exceeds a threshold range, the second flow of diluent greater than the first flow of diluent.

In still another aspect, an extraction room in a modular cube structure includes a bio-matter processing enclosure. An equipment enclosure shares a wall in common with the bio-matter processing enclosure. The equipment enclosure includes at least one of a bio-matter processing enclosure supply fan and a bio-matter processing enclosure exhaust fan. An exhaust stack is coupled in flow communication with the bio-matter processing enclosure. A first wall of the exhaust stack forms an interior wall of the bio-matter processing enclosure. A second wall of the exhaust stack forms an exterior wall of the extraction room. The exhaust stack extends through the equipment enclosure to an ambient space external to the extraction room. A vent connection is coupled in flow communication between the bio-matter processing enclosure and the exhaust stack.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-8 show example embodiments of the method and apparatus described herein.

FIG. 1 is a plan view of an example umbilical corridor coupled to a plurality of modular cube structures in accordance with an example embodiment of the present disclosure.

FIG. 2 is a perspective end view of the corridor segment shown in FIG. 1.

FIG. 3 is a plan view of a plurality of corridor segments coupled together end-to-end to form an umbilical corridor.

FIG. 4 is a plan view of another example of a modular cube structure that may be used with the umbilical corridor shown in FIG. 1.

FIG. 5 is a plan view of an example of a joint between adjacent ones of the umbilical corridor segments shown in FIG. 1.

FIG. 6 is a front elevation view of the third extraction room shown in FIG. 5 that may be used for an extraction step of the process.

FIG. 7 is a side elevation view of the third extraction room.

FIG. 8 is a flow chart of an example method of extracting a component of a quantity of bio-matter.

Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. Any feature of any drawing may be referenced and/or claimed in combination with any feature of any other drawing.

Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of the disclosure. These features are believed to be applicable in a wide variety of systems including one or more embodiments of the disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.

DETAILED DESCRIPTION

The following detailed description illustrates embodiments of the disclosure by way of example and not by way of limitation. It is contemplated that the disclosure has general application to construction of modular facilities in industrial, commercial, and residential applications.

The following description refers to the accompanying drawings, in which, in the absence of a contrary representation, the same numbers in different drawings represent similar elements.

FIG. 1 is a plan view of an example umbilical corridor 100 coupled to a plurality of modular cube structures 102 in accordance with an example embodiment of the present disclosure. Umbilical corridor 100 is formed from a plurality of hollow elongate corridor segments 104 coupled together using flanges 106 formed integrally into each corridor segments 104. Corridor segments 104 have a predetermined length 108. Each of the plurality of corridor segments 104 includes a first end flange 110 couplable to a complementary second end flange 112 of an adjacent one of the plurality corridor segments 104. Each of the plurality of corridor segments 104 may also include a side flange 114 couplable to a complementary end flange 116 of an adjacent modular cube structure 102. Each corridor segments 104 also includes a plurality of service conduits (not shown in FIG. 1) extending from end flange 116 of corridor segment 104 to at least the side flange 114 of the respective corridor segment 104. Typically, the plurality of service conduits extends from end flange 116 to an opposite end flange of corridor segment 104.

FIG. 2 is a perspective end view of a corridor segment 104 (shown in FIG. 1). In the example embodiment, corridor segment 104 includes a floor member 202 and a roof member 204 extending the predetermined length 108. Second end flange 112 circumscribes a hollow passageway interior 206. Second end flange 112 includes a plurality of members coupled together to provide a mating surface 208 for adjacent corridor segments 104 to be connected together. Second end flange 112 includes a vertical flange member 210 including a structural column member 212 and a cube corner assembly 214 fixedly coupled to at least one end of structural column member 212. In some embodiments, second end flange 112 includes a single cube corner assembly 214 in at least some corners of second end flange 112. In other embodiments, second end flange 112 includes a plurality of single cube corner assemblies 214 in at least some corners of second end flange 112. While described as being couplable together end-to-end, adjacent corridor segments 104 can also be configured to couple together side-by-side.

A plurality of service conduits 216 may extend between the first end flange 110 and second end flange (not shown in FIG. 2) within floor member 202 and/or within roof member 204. A distal end 218 of conduits 216 are fitted with couplings (not shown in FIG. 2) that are complementary with couplings of an adjacent corridor segment 104. In various embodiments, the plurality of service conduits include at least one of electrical supply conduits, control and instrumentation signal conduits, plumbing conduits, sewer/waste liquid conduits, heating, ventilating, and air conditioning (HVAC) conduits, and security and surveillance signal conduits.

FIG. 3 is a plan view of a plurality of corridor segments 104 coupled together end-to-end to form umbilical corridor 100.

FIG. 4 is a plan view of another example of a modular cube structure 102 that may be used with umbilical corridor 100 shown in FIG. 1. In the example embodiment, modular cube structure 102 includes a plurality of rooms, which may be configured to support a particular step of a process. The process may entail the cultivation of plant or animal life, the harvesting of the plant or animal life, processing the plant or animal life, extracting valuable materials from the plant or animal life, and preparing the residue of the plant or animal life for disposal. Some of the rooms are configured to support potentially hazardous operational steps or hazardous material within them. Some of the rooms may be subject to industrial codes or other restrictions on their construction or processes. For example, a first room 402 may be a production/operation where aspects of the process are carried out, initiated, monitored, and/or controlled. A second room 404 may include a freezer 406 and an area 408 that supports freezer process operations. A third room 410 may be used for an extraction step of the process. An extraction step may remove the valuable material from the plant or animal life being processed. Such a step may yield the valuable component being sought, waste gases, and waste solids. The waste gases may need to be captured for a forced air exhaust system 412 and exhausted outside modular cube structure 102 before the waste gas builds to a hazardous concentration. In the example embodiment, a fourth room 414 includes two additional production rooms 416 and 418 to facilitate increasing production levels of the valuable component.

FIG. 5 is a plan view of an exemplary joint 500 between adjacent ones of the umbilical corridor segments 104 (shown in FIGS. 1 and 2). A plurality of service conduits 216 may extend between the first end flange 110 and second end flange 112 within floor member 202 and/or within roof member 204 (shown in FIG. 2). A distal end 218 of conduits 216 are fitted with couplings 502 that are complementary with couplings 504 of an adjacent corridor segment 104. In some embodiments, pigtails 506 are used to bridge a gap 508 between couplings 502 and 504. Each pigtail 506 includes a length 510 of appropriate conduit 512 and mating couplings 514 on each end 516.

FIG. 6 is a front elevation view of third extraction room 528 (shown in FIG. 5) that may be used for an extraction step of the process. FIG. 7 is a side elevation view of third extraction room 528. In the example embodiment, third extraction room 528 in modular cube structure 102 (shown in FIG. 1) includes a processing enclosure 602, an equipment enclosure 604, and an exhaust stack 606. A first wall 608 of exhaust stack 606 forms an interior wall 610 of processing enclosure 602. A second wall 612 of exhaust stack 606 forms an exterior wall 614 of third extraction room 528. Exhaust stack 606 extends through equipment enclosure 604 to an ambient space 616 external to third extraction room 528.

Third extraction room 528 is coupled in flow communication to equipment enclosure 604 through a first filter assembly 618 and coupled in flow communication to exhaust stack 606 through a second filter assembly 620. Exhaust stack 606 includes a riser 622 positioned between interior wall 610 of processing enclosure 602 and exterior wall 614 of third extraction room 528. Exhaust stack 606 also includes a transition piece 624 coupled in flow communication with riser 622 and extends through equipment enclosure 604. Exhaust stack 606 further includes an exhaust fan 626 configured to draw air and/or a diluent from processing enclosure 602 and direct it to ambient space 616.

Equipment enclosure 604 includes a make-up fan 628 configured to supply a flow 630 of fresh air from ambient space 616 to equipment enclosure 604. Third extraction room 528 includes a fan balance controller 632 configured to maintain a predetermined pressure within processing enclosure 604. Fan balance controller 632 is also configured to maintain a predetermined flow through processing enclosure 604. Fan balance controller 632 includes at least one of a flow sensor 634 and a pressure sensor 636 configured to supply signals to fan balance controller 632 relative to a flow into processing enclosure 602 and a pressure within processing enclosure 602, respectively. Fan balance controller 632 further includes a hydrocarbon gas sensor 638 configured to initiate an off-normal operational sequence of fans 626 and 628 to increase air and/or diluent flow through processing enclosure 604 when a hydrocarbon gas concentration in processing enclosure 604 exceeds a predetermined value. Third extraction room 528 includes a conditioned air supply duct 640 coupled in flow communication with a heat pump or other flow conditioner (not shown in FIG. 6) to maintain a selectable temperature within processing enclosure 604. A vent connection extends from processing enclosure 602 directly into exhaust stack 606 for venting pressurized containers.

FIG. 8 is a flow chart of an example method 800 of extracting a component of a quantity of bio-matter. In the example embodiment, method 800 includes maintaining 802 a first flow of diluent through a processing enclosure of a multi-enclosure extraction room of a modular cube structure, the extraction room including an equipment enclosure and an exhaust stack. Method 800 also includes discharging 804 the first flow of diluent from the processing enclosure to the exhaust stack, a first wall of the exhaust stack forming an interior wall of the processing enclosure, a second wall of the exhaust stack forming an exterior wall of the extraction room, the exhaust stack extending through the equipment enclosure to an ambient space external to the extraction room. Method 800 further includes monitoring 806 a concentration of at least one solvent of a plurality of solvents used in the extraction process, receiving 808 a container of bio-matter into the processing enclosure, and maintaining 810 a second flow of diluent through a processing enclosure when the concentration of the at least one monitored solvent exceeds a threshold range, the second flow of diluent greater than the first flow of diluent.

In some embodiments, the multi-enclosure extraction room includes an equipment enclosure and an exhaust stack. Method 800 optionally includes receiving a container of bio-matter into the processing enclosure of the multi-enclosure extraction room. In various embodiments, fan balance controller 632 is configured to maintain a negative pressure in the processing enclosure using fans 626 and/or 628 positioned in the equipment enclosure or the exhaust stack. In other embodiments, method 800 includes receiving a container of bio-matter into the processing enclosure that includes a solvent within the container. The solvent may be in a gaseous, liquid, or supercritical form and may be under pressure within the container. In such a case, the solvent may leak into the processing enclosure and present a problem for equipment and for personnel working within the processing enclosure. Any pressure in the container may be vented through a vent connection to the exhaust stack from the processing enclosure. In some embodiments, it may be necessary to repressurize the container with the same or a different solvent.

The foregoing detailed description illustrates embodiments of the disclosure by way of example and not by way of limitation. It is contemplated that the disclosure has general application to construction of components within structures, in particular, modular structures. It is further contemplated that the methods and systems described herein may be incorporated into existing construction systems and structures, in addition to being maintained as a separate stand-alone structure.

It will be appreciated that the above embodiments that have been described in particular detail are merely example or possible embodiments, and that there are many other combinations, additions, or alternatives that may be included. While the disclosure has been described in terms of various specific embodiments, it will be recognized that the disclosure can be practiced with modification within the spirit and scope of the claims.

Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

Also, as used herein, the terms “substantially” or “about” are intended to indicate a condition within reasonably achievable manufacturing and assembly tolerances, relative to an ideal desired condition suitable for achieving the functional purpose of a component or assembly. By way of an example, an assembly of components in “substantial” alignment to a common axis of rotation may deviate from perfectly co-axial alignment so long as all the components can rotate as intended for accomplishing the functional purpose of the assembly.

The above-described embodiments of a valuable oil product extraction room in a modular cube structure provides a cost-effective and reliable means for providing a safe and efficient processing space in a modular and expandable multi-use facility. More specifically, the extraction room described herein facilitates maintaining an adequate purge air and/or other diluent flow through the extraction room. In addition, the above-described extraction room provides monitoring of off-normal concentrations of hazardous gases and initiating remedial operations until the off-normal condition is clear. As a result, the extraction room described herein facilitates a safe and efficient processing space in a cost-effective and reliable manner.

This written description uses examples to describe the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

What is claimed is:
 1. An extraction room in a modular cube structure, said extraction room comprising: a processing enclosure; an equipment enclosure; and an exhaust stack, a first wall of said exhaust stack forming an interior wall of the processing enclosure, a second wall of the exhaust stack forming an exterior wall of said extraction room, said exhaust stack extending through said equipment enclosure to an ambient space external to said extraction room.
 2. The extraction room of claim 1, wherein said extraction room is coupled in flow communication to said equipment enclosure through a first filter assembly.
 3. The extraction room of claim 1, wherein said extraction room is coupled in flow communication to said exhaust stack through a second filter assembly.
 4. The extraction room of claim 1, wherein said exhaust stack comprises: a riser positioned between said interior wall of said processing enclosure and said exterior wall of said extraction room; a transition piece coupled in flow communication with said riser and extending through said equipment enclosure; and an exhaust fan.
 5. The extraction room of claim 1, wherein said equipment enclosure comprises a make-up fan configured to supply fresh air from the ambient space to said equipment enclosure.
 6. The extraction room of claim 1, further comprising a fan balance controller configured to maintain a predetermined pressure in said processing enclosure.
 7. The extraction room of claim 1, further comprising a fan balance controller configured to maintain a predetermined flow through said processing enclosure.
 8. The extraction room of claim 1, further comprising a fan balance controller comprising at least one of a flow sensor and a pressure sensor.
 9. The extraction room of claim 1, further comprising a fan balance controller comprising a hydrocarbon gas sensor.
 10. The extraction room of claim 1, further comprising a conditioned air supply duct to maintain a selectable temperature in said processing enclosure.
 11. A method of extracting a component of a quantity of bio-matter includes: maintaining a first flow of diluent through a processing enclosure of a multi-enclosure extraction room of a modular cube structure, the extraction room including an equipment enclosure and an exhaust stack; discharging the first flow of diluent from the processing enclosure to the exhaust stack, a first wall of the exhaust stack forming an interior wall of the processing enclosure, a second wall of the exhaust stack forming an exterior wall of the extraction room, the exhaust stack extending through the equipment enclosure to an ambient space external to the extraction room; monitoring a concentration of at least one solvent of a plurality of solvents used in the extraction process; receiving a container of bio-matter into the processing enclosure; and maintaining a second flow of diluent through a processing enclosure when the concentration of the at least one monitored solvent exceeds a threshold range, the second flow of diluent greater than the first flow of diluent.
 12. The method of claim 11, wherein receiving a container of bio-matter into a processing enclosure of an extraction room comprises receiving a container of bio-matter into a processing enclosure of a multi-enclosure extraction room having an equipment enclosure and an exhaust stack.
 13. The method of claim 11, further comprising maintaining a negative pressure in the processing enclosure using a fan positioned in the equipment enclosure.
 14. The method of claim 11, wherein receiving a container of bio-matter into the processing enclosure comprises receiving a container of bio-matter into the processing enclosure including a solvent within the container.
 15. The method of claim 11, wherein receiving a container of bio-matter into the processing enclosure comprises receiving a container of bio-matter into the processing enclosure including a solvent under pressure within the container.
 16. The method of claim 11, wherein receiving a container of bio-matter into the processing enclosure further comprises venting the container to the exhaust stack.
 17. The method of claim 11, wherein receiving a container of bio-matter into the processing enclosure further comprises pressurizing the container with a solvent.
 18. An extraction room in a modular cube structure, said extraction room comprising: a bio-matter processing enclosure; an equipment enclosure sharing a wall in common with said bio-matter processing enclosure, said equipment enclosure comprising at least one of a bio-matter processing enclosure supply fan and a bio-matter processing enclosure exhaust fan; an exhaust stack coupled in flow communication with said bio-matter processing enclosure, a first wall of said exhaust stack forming an interior wall of the bio-matter processing enclosure, a second wall of the exhaust stack forming an exterior wall of said extraction room, said exhaust stack extending through said equipment enclosure to an ambient space external to said extraction room; and a vent connection coupled in flow communication between said bio-matter processing enclosure and said exhaust stack.
 19. The extraction room of claim 18, wherein said extraction room is coupled in flow communication to said equipment enclosure through a first filter assembly.
 20. The extraction room of claim 18, further comprising a fan balance controller configured to maintain at least one of a predetermined pressure in and a predetermined flow through said processing enclosure based on at least one of a flow sensor and a pressure sensor. 